Lithium Battery Tab Bend Structure for Faster Cell Welding
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Solution Overview
Problem
Conventional lithium ion battery manufacturing processes are inefficient due to lengthy welding processes and excessive material consumption, particularly in the optimization of bus bars, which affects overall efficiency and space utilization.
Innovation Solution
The battery cell design incorporates laminated plate sets with bent tabs forming a book page-shaped structure, allowing for direct convergence and welding of end faces, reducing tab lengths and material consumption, and enabling quicker assembly into a shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional bus bar structures are used with straight tabs, then the welding process is lengthy and material consumption is excessive, but the manufacturing process is simple
Solution Approach 1:
The patent applies curvature by bending the straight tabs into arc-shaped configurations. The positive tab and negative tab are both bent into arcs with different curvature directions, transforming the conventional straight bus bar structure into a curved structure that enables end-face convergence and reduces welding requirements while maintaining structural integrity
Solution Approach 2:
The patent introduces a new spatial dimension by bending tabs in different directions (positive tab bent in one direction, negative tab bent in opposite direction) to achieve three-dimensional convergence of end faces. This dimensional transformation allows the tabs to meet at their ends without requiring extensive linear alignment, thus reducing welding process length
2Loss of substance
If longer tabs are used for conventional welding, then welding process is more thorough, but material cost increases and space utilization decreases
Solution Approach 1:
By bending the tabs into arc shapes, the patent reduces the linear length of tabs required while maintaining sufficient overlap area for reliable welding. The curved configuration allows end-face convergence with shorter tab extensions, directly reducing material consumption while preserving welding quality through adequate contact area
Solution Approach 2:
The patent changes the geometric parameters of the tabs by introducing curvature radius and bend angles. The positive tab is bent with a specific curvature radius, and the negative tab is bent with a different curvature radius, optimizing the balance between tab length reduction and welding reliability
3Volume of moving object
If straight tabs are used, then assembly is straightforward, but space utilization rate is low
Solution Approach 1:
The curved tab configuration allows the battery cell components to be arranged in a more compact three-dimensional layout. The arc-shaped tabs converge at the ends, enabling better space utilization within the battery cell structure compared to straight tabs that would require more linear space for alignment and connection
Data Source
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AI summary
Disclosed are a battery cell and a manufacturing method thereof, and a battery using the battery cell. The battery cell comprises a plurality of laminated plate sets, and each plate set is formed by laminating a positive plate, a separator and a negative plate; the positive plate is provided with a positive tab extending outwardly along the plate, and the positive tab is provided with a positive tab bend; or, the negative plate is provided with a negative tab extending outwardly along the plate, and the negative tab is provided with a negative tab bend; and a plurality of positive tab bends and/or negative tab bends of the plurality of laminated plate sets are laminated to form a bent book page-shaped structure.